Toy Ball Apparatus with Reduced Part Count

ABSTRACT

A toy ball apparatus is disclosed herein that includes a mesh defining an outer surface of the toy ball apparatus. The mesh includes four mesh components that are coupled together to enclose a closed volume, each mesh component including a plurality of loop structures, each loop structure having a curved inner perimeter surface formed to at least partially surround a hole communicating with the closed volume and surrounded at least partially by a polygonal outer perimeter. Each mesh component has cooperative mating surfaces formed along an outer perimeter of the mesh component, the cooperative mating surfaces being formed along at least a portion of the outer perimeter of each of a plurality of the loop structures in the mesh component. The adjacent mesh components are joined together along the cooperative mating surfaces.

CROSS REFERENCE TO RELATED APPLICATION

This application claims priority to U.S. Provisional Patent Application No. 61/368,635, filed Jul. 28, 2010, entitled TOY BALL APPARATUS WITH REDUCED PART COUNT, the entirety of which is hereby incorporated by reference for all purposes.

BACKGROUND

The outer surfaces of many conventional balls can be difficult to grasp for some people, particularly young children and infants who are still developing motor control, making catching and throwing such balls a challenge. This challenge, and its attendant frustration, is increased for persons engaged in one-handed grasping and throwing. One prior invention which addresses this difficulty is described in U.S. Pat. No. 6,729,984, entitled TOY BALL APPARATUS, filed by David Silverglate, the entire disclosure of which is herein incorporated by reference. The commercial embodiments of U.S. Pat. No. 6,729,984, offered under the brand name OBALL®, have been well-received in the marketplace, delighting parents and children alike.

While U.S. Pat. No. 6,729,984 describes balls that are easy to grasp, the balls have relatively complicated structures, with many component parts. A high part count can increase the costs of manufacturing, as more molds are required, and more parts must be assembled, consuming valuable time.

SUMMARY

The present disclosure addresses the above issue by providing a ball that is easy to grasp, but that features a smaller number of components, so that it is more easily manufactured. A toy ball apparatus is disclosed herein that includes a mesh defining an outer surface of the toy ball apparatus. The mesh includes four mesh components that are coupled together to enclose a closed volume, each mesh component including a plurality of loop structures, each loop structure having a curved inner perimeter surface formed to at least partially surround a hole communicating with the closed volume and surrounded at least partially by a polygonal outer perimeter. Each mesh component has cooperative mating surfaces formed along an outer perimeter of the mesh component, the cooperative mating surfaces being formed along at least a portion of the outer perimeter of each of a plurality of the loop structures in the mesh component. The adjacent mesh components are joined together along the cooperative mating surfaces.

This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter. Furthermore, the claimed subject matter is not limited to implementations that solve any or all disadvantages noted in any part of this disclosure.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a front exploded view of a toy ball apparatus according to an embodiment of the invention, showing four mesh components from which the toy ball apparatus is assembled, and drawn approximately to scale.

FIG. 2 is a top view of a mesh component of the toy ball apparatus of FIG. 1.

FIG. 3 is a front view of the mesh component of FIG. 2.

FIG. 4 is a side view of the mesh component of FIG. 2.

FIG. 5 is a top partial assembly view showing two of the mesh components of the toy ball apparatus of FIG. 1, as viewed from the top in FIG. 1.

FIG. 6 is a rear partial assembly view showing two of the mesh components of the toy ball apparatus of FIG. 1, as viewed from the left rear side in FIG. 1.

FIG. 7 is a left side partial assembly view showing two of the mesh components of the toy ball apparatus of FIG. 1, as viewed from the left side in FIG. 1.

FIG. 8 is a net diagram of the mesh components that form the truncated icosahedrons of the mesh of the toy ball apparatus of FIG. 1.

FIG. 9 is a front view of the assembled toy ball apparatus of FIG. 1.

FIG. 10 is a front view a toy ball apparatus according to another embodiment of the invention.

DETAILED DESCRIPTION

FIG. 1 is an exploded view of a toy ball apparatus 10 according to one embodiment of the present invention. Toy ball apparatus 10 includes a mesh 12 that defines an outer surface of the toy ball apparatus 10. The mesh 12 includes a plurality of mesh components 14 from which the mesh 12 is assembled. During manufacture, the mesh components 14 are first molded as separate components, and then assembled together by a suitable assembly process. During assembly, the plurality of mesh components 14 are coupled together to enclose a closed volume 20. In the embodiment illustrated in FIG. 1, the mesh 12 includes four mesh components 14, including a first mesh component 14 a, a second mesh component 14 b, a third mesh component 14 c, and a fourth mesh component 14 d.

Mesh 12 may be formed in a polyhedron shape such as a truncated icosahedron, which approximates a sphere. Other polyhedral shapes may also be used to approximate a sphere, or other ball shape. It will be appreciated that by using four mesh components, the number of mesh components has been reduced as compared to the ten mesh components which are disclosed in U.S. Pat. No. 6,729,984, which can result in reduced manufacturing costs. As discussed below, the particular shape of the mesh components also simplifies molding, since the mesh components 14 may be molded in a mold without overhang portions that would make removal of the part from the mold difficult, as discussed in more detail below.

Each mesh component 14 includes a plurality of loop structures 15. In the illustrated embodiment, these loop structures 15 are categorized into a plurality of smaller loop structures 16 and a plurality of larger loop structures 18. Each loop structure 15 has a curved inner perimeter surface formed to at least partially surround a hole 92 communicating with the closed volume 20. The hole is sized to accommodate passage of one or more digits of the user into the closed volume, to enable grasping of toy ball apparatus 10 by the loop structures 15.

Further, each loop structure 15 is surrounded at least partially by a loop structure perimeter, which may be polygonal. In the illustrated embodiment, the smaller loop structures 16 are bounded by pentagonal loop structure perimeters formed around all or part of the smaller loop structure 16, while larger loop structures 18 are bounded by hexagonal loop structure perimeters formed around all or part of the lager loop structure. The loop structures 15 of each mesh component 14 are integrally molded together, and as a result all or a portion of the loop structure perimeters of each individual loop structure may be integrally molded with one or more adjacent loop structures of the same mesh component.

It will be further appreciated that each mesh component includes cooperative mating surfaces 19 formed on an outer perimeter of the mesh component. The cooperative mating surfaces 19 are formed along at least a portion of the loop structure perimeters of a plurality of the loop structures 15 in the mesh component, and adjacent mesh components 14 are joined together along the cooperative mating surfaces 19 to form mesh 12. Since the outer perimeter of each mesh component 14 is formed by portions of the loop structure perimeters of each loop structure 15 that bounds the edge of the mesh component 14, it will be appreciated that the cooperative mating surfaces 19 of each mesh component 14 are formed by part of the loop structure perimeters of a plurality of loop structures 15 in the assembly. Thus, the external edges, shown at 16 b and 18 b in FIGS. 2-4, of the loop structure perimeters also function as the cooperative mating surfaces 19 of each mesh component 14.

As discussed above, loop structures 15 may be sized to receive the fingers of a user's hand, such as a child's hand. The inner perimeter surfaces of the loop structures 15, such as inner perimeter surfaces 16 a and 18 a of loop structures 16 and 18, respectively, are typically curved, and may be continuously curved around their entire perimeter. In some examples, the inner perimeter surfaces may be circular. In other examples, the inner perimeter surfaces may be oval, or formed of complex curves. Some of the inner perimeter surfaces may have straight portions joined by curved portions, rather than corners. In this way, user discomfort from gripping the ball at sharp angular junctions, such as the corner of a square or pentagon, may be avoided. Further, for example, when a small hand inserts fingers into the holes of adjacent loop structures 15 and clenches to grip the ball, the curved inner perimeter surfaces gently guide the fingers toward each other and toward a vertex of the mesh, thereby promoting a secure grip on the toy ball apparatus 10 without discomfort on the fingers of the hand.

The shape and number of the mesh components 14 are designed in a manner that decreases manufacturing costs incurred using a process such as injection molding. Regarding the number of mesh components 14, it will be appreciated that when four mesh components 14 are utilized the production time may be significantly reduced when compared to a toy ball apparatus 10 having ten mesh components. The decreased production time may in turn decrease the toy ball apparatus's manufacturing cost.

Further, the shape of each mesh component 14 features no overhang portions and has a shape that, while curved, is typically constrained to have no more than 90° degrees of internal curvature (270° of external curvature). With such a shape, complicated molding techniques, such as the use of molds with sliders, may be avoided, also helping to control manufacturing costs, and in some cases multiple mesh components may be produced in a single mold cycle with a single mold. Specifically, as illustrated in FIG. 1, each mesh component includes both hexagonal loop structures 18 and pentagonal loop structures 16, and the hexagon-hexagon external dihedral angle α is approximately 217° and the corresponding hexagon-hexagon internal dihedral angle is approximately 143° (142.62°), while the pentagon-hexagon external dihedral angle β is approximately 222° and the corresponding pentagon-hexagon internal dihedral angle is approximately 138° (138.19°). As can be seen in FIG. 1, the mesh component 14 a has a maximum internal curvature of less than 90 degrees, which prevents molded components from having undercut regions. The maximum internal curvature of the depicted mesh component is formed where two hexagon loop structures and one pentagon loop structure are linked together, along the same arc, resulting in an internal curvature of (180−143)+(180−138)=79° (computed by summing the difference between 180 degrees and the internal dihedral angle, for each of the internal dihedral angles). Put another way, each mesh component has a maximum aggregate external dihedral angle of less than 270 degrees. Along the same stretch of two hexagonal loop structures and one pentagon loop structure, the aggregate external dihedral angle equals (217+(222−180))=259° (computed by summing the first external dihedral angle and the difference between 180 and each of the remaining external dihedral angles along a path in the mesh component). Line 91 in FIG. 8 illustrates one exemplary location of such a path on the mesh component at which the maximum internal and external curvatures are reached. It will be appreciated that other locations on the same mesh component have similar geometries (hexagon-hexagon-pentagon) and accordingly have the same maximum internal and external curvatures. While 79 degrees of maximum internal curvature and the corresponding 259 degrees maximum aggregate external curvature are depicted in the illustrated embodiment, it will be appreciated that other embodiments may have internal curvatures of between 70 and 90 degrees, or between 250 and 270 degrees of external curvature.

FIGS. 2-4 respectively show top, front and side views of a single mesh component 14 a. Although a single mesh component 14 a is shown in these figures it will be appreciated that each of mesh components 14 a-14 d is substantially identical in size and shape in the depicted embodiment. As shown, each mesh component includes eight loop structures, including three smaller loop structures 16 and five larger loop structures 18. An outer loop structure perimeter of each of the smaller loop structures 16 is pentagonal and an outer loop structure perimeter of each of the larger loop structures 18 is hexagonal. The outer loop structure perimeter of each loop structure 15 includes edges that may be internal or external to the mesh component 14. For example, external edges 16 b of loop structures 16 and external edges 18 b of loop structures 18 collectively surround the outer perimeter of the depicted mesh component 14 a. On the other hand, internal edges 18 c are formed along edges of the loop structures in an internal region of the mesh component 14 a. Further, it will be appreciated that each of the smaller loop structures 16 is typically spaced apart from the other smaller loop structures 16. That is to say, the outer loop structure perimeters of the smaller loop structures 16 are typically not in direct contact with each other. In the mesh component 14 a, one hexagonal loop structure 18 is bordered by only internal edges 18 c, and is not bordered by any external edges 18 b.

The loop structures 15 are arranged to form each mesh component 14 in such a manner that each mesh component 14 includes an outer perimeter having 17 external edges. As one example, these external edges are labeled A1-A17 for mesh component 14 a in FIG. 8. Each mesh component 14 includes 8 faces (in which holes 92 are positioned), 14 vertices, and 31 edges (along which the loop structures 15 are formed). Of these 31 edges, 14 are internal edges such as internal edges 18 c in FIGS. 2-4, and 17 are external edges such as external edges 16 b, 18 b in FIGS. 2-4.

It will be appreciated that other geometric configurations for the mesh 12 and mesh components 14 may be utilized in other embodiments. As one example, the mesh components 14 may take the form of other polyhedral segments, and thus the loop structures may be shaped in the form of other polygons or curves, alternatively or in addition to the hexagon and pentagon shaped loop structures. As another example, the mesh components 14 may be formed entirely of loop structures having outer perimeters shaped as pentagons, which are assembled to make a dodecahedron-shaped ball. Other embodiments of the mesh 12 of the toy ball apparatus 10 may be formed as a rhombicosidodecahedron, truncated icosidodecahedron, or snub dodecahedron, as some examples. As another variation, some or all of the loop structures may be filled in with material, so that they do not contain any curved inner perimeter surface. In this way, material may span the entirety of the interior of each loop structure, to create a partially or completely solid surface.

FIGS. 5-7 show mesh component 14 a respectively coupled to mesh components 14 d, 14 c and 14 b. These figures provide illustrations of the mating surfaces 19 of the mesh components in various orientations, and possible examples of how the components may be fitted into a single mold during the molding process. In particular, FIG. 5 shows mating surfaces 19 of mesh component 14 a arranged to contact with mating surfaces 19 of mesh component 14 d, as viewed from the top in FIG. 1. FIG. 6 shows mating surfaces 19 of mesh component 14 a arranged to contact with mating surfaces 19 of mesh component 14 c, as viewed from the rear in FIG. 1. FIG. 7 shows mating surfaces 19 of mesh component 14 a arranged to contact with mating surfaces 19 of mesh component 14 b, as viewed from the left side in FIG. 1. FIGS. 5-7 also illustrate that neither of the mesh components shown in the orientations in each of FIGS. 5-7 include any overhang regions, which would otherwise be visible in the background through the holes in the mesh, but noticeably are not visible. This is due to the maximum internal curvature of each mesh component 14 being less than 90 degrees, in some embodiments between about 70 and 90 degrees, and most specifically about 79 degrees. The lack of overhang regions facilitates the use of simple molds during the injection molding process, as described above.

FIG. 8 is a diagram showing a net of the toy ball apparatus 10 and its constituent mesh components 14 a-14 d. In this net representation, the mesh components 14 a-14 d have been flattened and schematically represented as pentagons and hexagons. Internal edges (such as internal edges 18 c in FIG. 2) of the loop structures 15 within each mesh component that are connected to one another are indicated in dashed lines 93 where the edges have been separated due to flattening. The connections between these separated internal edges are represented by dot dashed lines. External edges (such as external edges 16 b and 18 b described above) along the outer perimeter of each mesh component are drawn in solid lines, and connections between the external edges on the outer perimeter of each mesh component and external edges of other mesh components are also indicated by dot dashed lines. In this manner it can be seen how each external edge is joined with another corresponding external edge when the mesh components 14 a-14 d are assembled. For ease of understanding, each external edge of each mesh component has been respectively labeled A1-A17, B1-B17, C1-C17, and D1-D17 on mesh components 14 a, 14 b, 14 c, and 14 d. As an example, D6 is an external edge on the outer perimeter of mesh component 14 d, which is joined to external edge C6 during assembly.

FIG. 9 illustrates toy ball apparatus 10 in its assembled state, in which the plurality of mesh components 14 a, 14 b, 14 c, and 14 d have been coupled to enclose the closed volume 20 and form the mesh 12, by joining adjacent mesh components 14 along their cooperative mating surfaces 19 and securing the mesh components 14 together, for example, by plastically welding the mesh components 14 together along the cooperative mating surfaces 19. The assembled toy ball apparatus 10 has an outer surface in the form of a truncated icosahedron, which has 32 faces, 90 edges, and 60 vertices. A seam or parting line 94 may be visible, showing the divisions between the mesh components in the assembled ball. By plastically welding the mesh components, toxic adhesives may be avoided, and the structural integrity of the assembled toy ball apparatus may be promoted. Alternatively, other joining and securing techniques may be used which are not toxic and which offer suitable structural integrity.

It will be appreciated that when fewer mesh components are utilized in the toy ball apparatus the number of seams or parting lines is also decreased. During the manufacturing process, each seam is mated, and then reworked or finished to produce the final product. Thus, by decreasing the seam count of the toy ball apparatus, the assembly, rework and finishing labor is also reduced, thereby helping to lower manufacturing costs. Further, in embodiments that are not plastically welded, but are bonded with adhesive, the structural integrity of the toy ball apparatus may be increased when the number of seams is decreased, due to the fact that the adhesively bonded seams generally do not have as much structural integrity as the molded mesh components. Further, by reducing part count, it becomes easier to employ an automated process, as opposed to manual labor, to couple the mesh components to form the toy ball apparatus, to further reduce manufacturing costs.

Toy ball apparatus 10 is typically formed of a plastic, such as a thermoplastic, which may have a shore “A” hardness of between approximately 50 and 150. As a result, toy ball apparatus 10 may be resiliently deformable. It will be appreciated that toy ball apparatus 10 may be at least partially deformed into the closed volume 20 that is surrounded by mesh 12. Typically, once a force, or object, causing such deformation is removed from toy ball apparatus 10, the resilient character of mesh 12 results in toy ball apparatus 10 substantially returning to its original shape. Due to mesh 12 being substantially deformable and substantially resilient, toy ball apparatus 10 may bounce when thrown against an object or impediment. Such deformability and resiliency of toy ball apparatus 10 may also make it more comfortable to catch and throw as compared to prior devices. In some embodiments, materials of different hardness and rigidity may be combined in the same toy ball apparatus 10. Further, in some embodiments a more rigid material may be used to manufacture the toy ball apparatus 10, for example, to provide a ball with superior bounce characteristics.

One potential advantage of the above described toy ball apparatus over the toy ball apparatus described in U.S. Pat. No. 6,729,984 is that by reducing the component count by 60% from ten to four, manufacturing costs may be significantly reduced. Another potential advantage is that by using mesh components that do not have overhang regions, manufacturing of these mesh components may be accomplished using molds that do not incorporate complicated and costly sliders. These advantages are simply illustrative, and not exhaustive.

FIG. 10 illustrates a toy ball apparatus 100 according to another embodiment of the invention. Toy ball apparatus 100 is similar in many respects to toy ball apparatus 10 described above, and such similarities will not be re-described for the sake of brevity. Toy ball apparatus 100 includes a mesh 112 that surrounds a closed volume, the mesh 112 being formed of a plurality of interlinked loop structures 115. In this embodiment, the mesh 112 is formed in the shape of a truncated icosahedron and the loop structures 115 have hexagonal and pentagonal outer loop structure perimeters.

The loop structures 115 include inner perimeters that have a plurality of straight portions 119 joined at radiused corners, the straight portions 119 and radiused corners collectively defining substantially hexagonal and pentagonal inner perimeter surfaces of the loop structures. Some of the loop structures 115 include inner perimeter surfaces that bound a hole that communicates with the closed volume, and other of the loop structures are fitted with a spanning structure 117, which is a plate-shaped structure bounded by an inner perimeter of the loop structure in which it is fitted. Thus, only a subset of the loop structures 115 include holes, while another subset of the loop structures 115 include the solid spanning structure 117. In the embodiment of FIG. 10, the spanning structures 117 are pentagonal, and are positioned in loop structures with pentagonal outer loop structure perimeters symmetrically about the mesh 112. The toy ball apparatus 100 may be manufactured of four mesh components as described above in relation to toy ball apparatus 10, with a parting line between the mesh components of substantially the same configuration as shown in FIG. 9. In addition to the manufacturing advantages of having a comparatively low part count discussed above, it will be appreciated that the configuration of toy ball apparatus 100 provides the external appearance of a soccer ball through solid spanning structures 117 and straight portions 119 on the loop structure inner perimeter surfaces, while retaining the resilient deformability and reduced wind resistance provided by having holes in many of the loop structures.

It will be appreciated that the configurations and/or approaches described herein are exemplary in nature, and that these specific embodiments or examples are not to be considered in a limiting sense, because numerous variations are possible. The subject matter of the present disclosure includes all novel and nonobvious combinations and subcombinations of the various features, functions, acts, and/or properties disclosed herein, as well as any and all equivalents thereof. 

1. A toy ball apparatus having a surface, the apparatus comprising: a mesh defining an outer surface of the toy ball apparatus, the mesh including four mesh components that are coupled together to enclose a closed volume, each mesh component including a plurality of loop structures, each loop structure having a curved inner perimeter surface formed to at least partially surround a hole communicating with the closed volume and surrounded at least partially by a polygonal outer perimeter, each mesh component having cooperative mating surfaces formed along an outer perimeter of the mesh component, the cooperative mating surfaces being formed along at least a portion of the outer perimeter of each of a plurality of the loop structures in the mesh component, wherein adjacent mesh components are joined together along the cooperative mating surfaces.
 2. The toy ball apparatus of claim 1, wherein each mesh component includes eight loop structures.
 3. The toy ball apparatus of claim 2, wherein each mesh component includes three smaller loop structures and five larger loop structures.
 4. The toy ball apparatus of claim 3, wherein the smaller loop structures are pentagonal and the larger loop structures are hexagonal.
 5. The toy ball apparatus of claim 2, wherein each mesh component includes an outer perimeter having 17 external edges.
 6. The toy ball apparatus of claim 1, wherein each mesh component has a maximum internal curvature of less than 90 degrees.
 7. The toy ball apparatus of claim 1, wherein each mesh component has a maximum aggregate external dihedral angle of less than 270 degrees.
 8. The toy ball apparatus of claim 2, wherein each mesh component includes 8 faces, 14 vertices, and 31 edges, of which 14 are internal edges and 17 are external edges.
 9. The toy ball apparatus of claim 1, wherein the mesh components are identical in shape and size.
 10. The toy ball apparatus of claim 1, wherein each mesh component is injection molded.
 11. The toy ball apparatus of claim 1, wherein a parting line is formed along an outer surface of the mesh where the mesh components are joined to each other.
 12. The toy ball apparatus of claim 1, wherein the mesh is plastic and resiliently deformable.
 13. The toy ball apparatus of claim 1, wherein the inner perimeter surfaces are continuously curved.
 14. The toy ball apparatus of claim 1, wherein the inner perimeter surfaces are circular.
 15. The toy ball apparatus of claim 1, wherein the mesh is formed in the shape of a truncated icosahedron.
 16. A toy ball apparatus having a surface, the apparatus comprising: a mesh including four coupled mesh components which together form a truncated icosahedron and enclose a closed volume, each mesh component including a plurality of loop structures, each loop structure having a continuously curved inner perimeter surface formed to surround a hole communicating with the closed volume and surrounded at least partially by a polygonal outer perimeter, each mesh component having cooperative mating surfaces formed along an outer perimeter of the mesh component, the cooperative mating surfaces being formed along at least a portion of the outer perimeter of each of a plurality of the loop structures in the mesh component; wherein each mesh component has a maximum internal curvature of less than 90 degrees; and wherein adjacent mesh components are joined together along the cooperative mating surfaces; and wherein the mesh is made of plastic and is resiliently deformable.
 17. The toy ball apparatus of claim 16, wherein the mesh is formed in the shape of a truncated icosahedron.
 18. The toy ball apparatus of claim 17, wherein each mesh component includes three smaller loop structures and five larger loop structures, the smaller loop structures being pentagonal and the larger loop structures being hexagonal.
 19. The toy ball apparatus of claim 16, wherein the mesh components are identical in shape and size.
 20. A toy ball apparatus having a surface, the apparatus comprising: a mesh including four coupled mesh components which together enclose a closed volume, each mesh component being identical in size and shape, and including a five larger loop structures with hexagonal outer perimeters and three smaller loop structures with pentagonal outer perimeters, each loop structure having a curved inner perimeter surface formed to surround a hole communicating with the closed volume and surrounded at least partially by a polygonal outer perimeter, each mesh component having cooperative mating surfaces formed along an outer perimeter of the mesh component, the cooperative mating surfaces being formed along at least a portion of the outer perimeter of each of a plurality of the loop structures in the mesh component, wherein adjacent mesh components are joined together along the cooperative mating surfaces, wherein the mesh is made of plastic and is resiliently deformable. 